Model No. TL1000PWC TL1000PWCE

Transcription

1 3/05 ML003, REV.4 Model No. TL1000PWC TL1000PWCE ASSEMBLY INSTALLATION REPLACEMENT PARTS READ complete manual CAREFULLY BEFORE attempting operation Lift Capacity 1000lbs. Maximum Beam Width 56 LAKESIDE LIFT Dethmers Mfg. Co th St. P.O. Box 189 Boyden, IA PH: (71) 75-1 Toll Free: Fax: (71) Page 1

2 1. Unless otherwise specified, high-strength SAE 5 (grade 5)(3 radial-line head markings) hex head bolts are used throughout assembly of this piece of equipment. See page 8.. Whenever terms "LEFT "and "RIGHT" are used in this manual it means from a position that boat enters hoist and facing forward. GENERAL INFORMATION TABLE OF CONTENTS OPERATING INSTRUCTIONS 3. When placing a parts order, refer to this manual for proper part numbers and place order by PART NO. and DESCRIPTION. Operating Instructions and Periodic Maintenance... Page Equipment Safety Guidlines... Page 4 Safety Sign Locations... Page 5 Safety Sign Care, Remember, & Before Operation... Page 6 Bolt Torque... Page 7 Tower Lift Assembly Instructions... Page 8 TL1000PWC Parts Breakdown and Instructions... Page 9 TL1000PWCE Parts Breakdown and Instructions... Page 10 TL1000PWC, TL1000PWCE Parts List... Page 11 Installation Instructions... Page 1 1. To operate Hand Wheel winch for the hoist, turn the handwheel clockwise to raise the cradle and turn the handwheel counter-clockwise to lower the cradle.. To raise the hoist using the electric winch, turn the switch to the raise position and to lower the hoist turn the switch to the lower position. Warning: To Prevent Personal Injury Only raise the cradle until it touches the upper stop. DO NOT raise hoist too high or the hoist may be damaged or cables may break. Also DO NOT lower hoist too low or cable may begin to wrap around the top side of the winch and may cause damage to cables. All persons should be off of the PWC before operating hoist or this could increase your gross weight over the hoist capacity and cause failure or injury. 3. To remove your PWC from the hoist, turn the handwheel counterclockwise to lower the cradle as far as necessary to release the PWC. 4. When entering the hoist, approach slowly until the PWC is on the center of the bunk mount boards. Then proceed to raise the cradle by turning the handwheel clockwise. 5. When the hoist is in the up position a padlock can be placed in the 1/" hole located on Upright Post. PERIODIC MAINTENANCE 1. Inspect the lift cable for worn, frayed or rusted areas periodically and replace as needed.. Tighten all bolts at the beginning and the end of each boating season. 3. Grease all zerks and the worm gear drive of the electric winch periodically with a high quality all purpose waterproof grease. Page

3 SAFETY TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND SAFETY OF OTHERS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH. THIS SYMBOL MEANS ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED! SIGNAL WORDS Note use of following signal words DANGER, WARNING, and CAUTION with safety messages. The appropriate signal word for each has been selected using the following guidelines: DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations typically for machine components which, for functional purposes, cannot be guarded. WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices. CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. If you have questions not answered in this manual, require additional copies, or if your manual is damaged, please contact your dealer or Dethmers Mfg. Co., P.O. Box 189, th Street, Boyden, IA 5134 ph: (71) 75-1 Toll Free: Fax: (71) Page 3

4 SAFETY...YOU CAN LIVE WITH IT EQUIPMENT SAFETY GUIDELINES Every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. You, the operator, can avoid many accidents by observing the following precautions in this section. To avoid personal injury, study following precautions and insist those working with you, or you yourself, follow them. In order to provide a better view, certain illustrations in this manual may show an assembly with a safety shield removed. However, equipment should never be operated in this condition. Keep all shields in place. If shield removal becomes necessary for repairs, disconnect power. Replace shield prior to use. Replace any caution, warning, danger or instruction safety decal that is not readable or is missing. Location of such decals is indicated in this booklet. Do not attempt to operate this equipment under the influence of alcohol or drugs. Review safety instructions with all users. Operator should be a responsible adult. DO NOT ALLOW PERSONS TO OPERATE OR ASSEMBLE THIS UNIT UNTIL THEY HAVE DEVELOPED A THOROUGH UNDERSTANDING OF SAFETY PRECAUTIONS AND HOW IT WORKS. Never exceed the limits of a lift. If its ability to do a job, or to do so safely is in question - DON'T TRY IT. Page 4

5 REV 0 ML106 SAFETY SIGN LOCATIONS Types of safety sign and locations on equipment are shown in illustration below. Good safety requires that you familiarize yourself with various safety signs, type of warning, and area or particular function related to that area, that requires your SAFETY AWARENESS. WARNING To prevent serious injury or death Do Not lift more than rated capacity. Refer to owners manual. LILIL DOCK OCKSIDE IFTER IL LIFTER TM WARNING To prevent serious injury or deat ' Do not play on or around unit when in use or stored DOWN h - U P By PAT. NO. 5,143,18 5,1,970 5,560,735 ML1010 ML1016 ML1006 Do not play on or around unit at any time. REV 1 ML1016 ML1016 BOYDEN, IA REV 1 ML1010 ML1010 WARNING ML1008 ML106 ML1016 DOCKSIDE LIL'LIFTERIFTER TM DETHMERS MFG.COMPANY th Street Boyden, IA ML106 To prevent serious injury or death KEEP AWAY, moving parts can crush and dismember DO NOT operate without guards and shields in place DISCONNECT AND LOCK out power source before adjusting and servicing REV 1 ML1006 ML1006 WARNING To prevent serious injury or death DO NOT re-use cable clamps.. Used clamps may fail to hold properly. Failure of clamps will cause lift to fall unexpectedly REV 1 ML1008 ML1008 Page 5

6 SAFETY SIGN CARE Keep safety signs clean and legible at all times. Replace safety signs that are missing or have become illegible. Replacement parts that displayed a safety sign should also display current sign. Safety signs are available from your distributor, dealer parts department, or factory. How to install safety signs: Be sure that installation area is clean and dry. Decide on exact position before you remove backing paper. Remove smallest portion of split backing paper. Align decal over specified area and carefully press small portion with exposed sticky backing in place. Slowly peel back remaining paper and carefully smooth remaining portion of decal into place. Small air pockets can be pierced with a pin and smoothed out using the piece of decal backing paper. REMEMBER Your best assurance against accidents is a careful and responsible operator. If there is any portion of this manual or function you do not understand, contact your local authorized dealer or manufacturer. BEFORE OPERATION: Carefully study and understand this manual. Do not wear loose-fitting clothing which may catch in moving parts. Always wear protective clothing. Give lift a visual inspection for any loose bolts, worn parts, or cracked welds, and make necessary repairs. Follow maintenance safety instructions included in this manual. Be sure there are no tools lying on or in equipment Do not use lift until you are sure that area is clear, especially around children and animals. Don't hurry learning process or take lift for granted. Ease into it and become familiar with your new lift. Practice operation of your lift and its attachments. Completely familiarize yourself and other operators with its operation before using. Page 6

7 BOLT TORQUE TORQUE DATA FOR STANDARD NUTS, BOLTS, AND CAPSCREWS. Tighten all bolts to torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt chart as guide. Replace hardware with same grade bolt. NOTE: Unless otherwise specified, high-strength Grade 5 hex bolts are used throughout assembly of equipment. Bolt Torque for Standard bolts * Torque Specifications GRADE GRADE 5 GRADE 8 A lb-ft (N.m) lb-ft (N.m) lb-ft (N.m) 1/4 6 (8) 9 (1) 1 (16) 5/16 10 (13) 18 (5) 5 (35) 3/8 0 (7) 30 (40) 45 (60) 7/16 30 (40) 50 (70) 80 (110) 1/ 45 (60) 75 (100) 115 (155) 9/16 70 (95) 115 (155) 165 (0) 5/8 95 (130) 150 (00) 5 (300) 3/4 165 (5) 90 (390) 400 (540) 7/8 170 (30) 40 (570) 650 (880) 1 5 (300) 630 (850) 970 (10) Bolt Torque for Metric bolts * Torque figures indicated are valid for non-greased or non-oiled threads and heads unless otherwise specfied. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%. * GRADE or CLASS value for bolts and capscrews are identified by their head markings. CLASS 8.8 CLASS 9.8 CLASS 10.9 A lb-ft (N.m) lb-ft (N.m) lb-ft (N.m) 6 9 (13) 10 (14) 13 (17) 7 15 (1) 18 (4) 1 (9) 8 3 () 5 (34) (4) (61) 50 (68) 61 (83) 1 78 (106) 88 (118) 106 (144) (169) 140 (189) 170 (30) (63) 16 (93) 63 (357) (363) (493) (513) (689) 516 (699) (95) (886) (106) GRADE- GRADE-5 GRADE-8 CLASS 8.8 CLASS 9.8 CLASS Page 7

8 TOWER LIFT ASSEMBLY INSTRUCTIONS 1. Bolt Roller Base Assembly (#17) to cradle (#0) using four 1/" x 1-1/4" bolts (#7), eight 1/" SS flatwashers (#), and four 1/" hex nuts (#3).. Slide the four Cradle Rollers (#18) and four 3/4" Adjustment Shims (#19) onto the Roller Shaft (#17). NOTE: The Adjustment shims should be used to maintain proper fit of the cradle assembly in the upright post. 3. If the rollers of the cradle fit too tight in the upright post, remove the adjustment shims one side of the cradle at a time until proper adjustment of a total gap of 1/16" to 1/8" between ends of the rollers and the sides of the upright is achieved. 4. Lower the roller base assembly with cradle assembly into the top of upright lift post (#6). NOTE: Go to step 4 on page 1 if you have the electric winch. 5. Attach Winch Mount Bracket (#10) to upright lifting post using four 3/8" x 1" bolts (#30), four 3/8" SS flatwashers (#),four 3/8 lock washers (#54), and four 3/8" hex nuts (#3). 6. Bolt the Winch (#8) to the winch mount bracket (#10) using three 3/8" x 1-1/4" SS bolts (#34), six SS flatwashers (#), three 3/8 SS Lockwashers(#54), and three hex nuts (3). Do not tighten nuts at this time. 7. Attach cable to winch as shown in the cable attachment diagram (view A or view B depending on which hardware is furnished with winch). 8. For routing the cable follow diagram, and pictures carefully. MANUAL WINCH: Begin by routing cable from winch down to roller base assembly. Assemble bottom sheave assembly (#16 & #15) with cable routed, and tied down as shown in diagram with a 1/" x -1/" bolt (#1), and a 1/" thin nylon insert locknut (#9). With plenty of slack route cable back up and assemble top sheave assembly (#16 & #15), with sheave brackets (#13 & #14) with cable routed as shown. Secure using one 1/" x 1-3/4" bolt (#33), two 1/" SS flatwashers (#), and one 1/" hex nut (#3). ELECTRIC WINCH: Route cable from winch down to roller base assembly. Assemble sheave assembly (#16 & #15), with cable routed as shown in diagram. Secure using one 1/" x - 1/" bolt (#1), and one 1/" thin nylon insert locknut (#9). Route cable back up and tie down at the top of upright post as shown using one 3/8" x - 1/" bolt (#36), two 3/8" flatwashers, and one 3/ 8" hex nut (#3). 9. The Winch Cover is attached by first inserting the slotted holes (B) of the cover between the bottom of the Winch Bracket (#10) and the top of the SS flat washer. Use two 3/8" x 3-1/" SS hex head bolts (#36), 3/8" SS flatwashers (#3), and 3/8" nylon lock nuts (#5) to hold winch cover (#7), top formed sheave bracket (#13), and top sheave bracket (#14) to upright post (#6). Do not overtighten. 10.Attach Cradle Stop (#55) using one more 3/8" x -1/" stainless steel bolt (#36), 3/8" SS flatwasher (#) and nylon locknut (#5) to upright leg *. Do not overtighten. 11.Mount the Winch Hand Wheel (#9) to the Winch (#8) using the nut and spring furnished with winch. 1.Slide Fork Tubes (#1) over the cradle (#0) I Extrusions, and secure with four 3/8" x 5-1/" bolts (#39), six 3/8" SS flatwashers, four 3/8" hex nuts (#3), and four 3/8 SS Lockwashers (#54). 13.Attach the four Bunk Board Mounting Angles (#3) to the Bunk Boards (#6) using eight 3/ 8" x 1-1/4" wood screws (#8), and eight 3/8" SS flatwashers. Bolt bracket (#) to bunk board bracket (#3) using four 3/8" x 1" bolts (#30), eight 3/8" SS flatwashers (#), four 3/ 8" locknuts (#5), four 1/" flatwashers (#), and four bushings (#5) Leave these bolts just loose enough that the weight of the boat will cause brackets (#3) to rotate and settle into a supportive position. IMPOR- TANT: After boat has been loaded for the first time, tighten the 3/8" x 1" bolts (#30) bolts that attach the bunkboards. 14.Mount bunk over cradle fork tubes using either set of holes in the formed bunkboard brackets (#). Mount using eight 3/8" x 4" SS bolts (#39), sixteen 3/8" SS flatwashers, Bunkboard Backplate (#4), eight 3/8" hex nuts (#3), and eight 3/8 SS Lockwashers (#54). Adjust to fit watercraft. 15.Attach Dock Plate (#4) to the lift assembly using the Dock Plate Backup Plates (#5), six 1/ " x " SS bolts (#35), twelve 1/" flatwashers (#), and six 1/" hex nuts (#3). Page 8

9 TL1000PWC PARTS BREAKDOWN B Included with Sea Lift only. VIEW B Put cable through & pinch between sideplate by tightening lock nut on backside Winch Reel Lock Nut Cable Clamp Cable VIEW A Page Kit HDW Includes Cable clamp, locknut & special bolt.

10 TL1000PWCE PARTS BREAKDOWN VIEW C TO CRADLE Included with Sea Lift ELECTRIC WINCH ASSEMBLY INSTRUCTIONS 4. Attach Electric Winch Mount Bracket (#43) to Upright Lift Post using four 3/8" x 1" hex head bolts (#30), 3/8" SS flatwashers (#) and 3/8" nuts (#3). 5. Bolt the Electric Winch (#44) to the Electric Winch Mount Bracket (#43) using three 3/8" x 1-1/4" SS bolts (#34), six SS flatwashers (#) and three nuts (#3). Note: Make sure the SS Shield Backplate (#45) is located between the Electric Winch Mount Bracket and the Electric Winch Route Cable (#4) (see also step 8 page ) counter clockwise around sheave in the roller base assembly (#17). Bolt the Looped end of the Cable (#4) to the Upright Post (#6) as shown using one 3/8" x -1/" SS bolt (#36), 3/8" SS flatwasher (#), and 3/8" nut (#44). Attach the cable to the Electric Winch (#44) as shown in the cable attachment diagram View C using the 3/ 16" cable clamp (#51). 7. Bolt the winch switch to either side of the Electric Winch Cover (#45) using two #10 x 3/4" screws (#46), #10 washer (#47), and #10 nut (#48). 8. Attach the Electric Winch Cover (#45) using two #8 screws (#49) that are furnished with the Electric Winch Cover Assembly Note: Return to step #10 on page 10. Page 10

11 TL1000PWC, TL1000PWCE PARTS LIST TL1000PWC TL1000PWCE REF. PART PART NO. NO. QTY NO. QTY DESCRIPTION /"-13 UNC x -1/" Hex Head Bolt - SS /" Flatwasher - SS /"-13 UNC Hex Nut Dock Plate Dock Plate Back-Up Plate Upright Post TL1000PWC - 5' Lift Height Upright Post TL1000PWC - 7' Lift Height Winch Cover Manual Winch Aluminum Winch Wheel Winch Bracket mm Hex Nut Revolving Handle f/ Tower Lift Handwheel Top Formed Sheave Bracket Top Sheave Bracket Sheave Bushing Sheave Roller Base Assembly Cradle Roller Roller Shim Washer Cradle Cradle Fork Tubes Formed Bunkboard Bracket Bunkboard Mtg. Angle Bunkboard Backplate Bushing.500 OD x.370 ID x Carpeted Bunkboard /"-13 UNC x 1-1/4" SS Hex Head Bolt /8" x 1-1/" Hex Head Wood Screw /"-13 UNC Thin Nylon Insert Locknut /8"-16 UNC x 1" Hex Head Bolt - SS /8" Flatwasher - SS /8"NC Hex Nut - SS /"-13 UNC x 1-3/4" Hex Head Bolt -SS /8"-16 UNC x 1-1/4" Hex Head Bolt - SS /"-13 UNC x " Hex Head Bolt - SS /8"-16 UNC x -1/" Hex Head Bolt - SS /8"-16 UNC x 3-1/" Hex Head Bolt - SS /8"-16 UNC x 4" Hex Head Bolt - SS /8"-16 UNC x 5-1/" Hex Head Bolt - SS Anode Bracket Anode /16" x 19" Cable w/ 3/16" Thimble (5 Ft.) /16 x 56 Cable w/ 3/16 Thimble (7Ft.) * /16 x 19 Cable w/ 3/16 Thimble, SS, (5Ft.) * /16 x 56 Cable w/ 3/16 Thimble, SS, (7Ft.) * /16 x 144 Cable w/ 3/16 Thimble, SS, (5Ft.) /16" x 144" Cable w/ 3/16" Thimble (5 Ft.) * /16" x168" Cable w/ 3/16" Thimble, SS, (7 Ft.) /16" x 168" Cable w/ 3/16" Thimble (7 Ft.) Electric Winch Bracket Electric Winch Assembly w/ Switch Assembly Electric Winch Cover Assembly #10-4UNC x 3/4"Slotted Round Head Screw #10 Washer #10-4UNC Hex Nut #8 Screw (furnished with Winch Cover Assy.) GFCI Inline Plug /16" Cable Clamp /8"-16 UNC Nylon Insert Locknut X 14 GA Machine Washer /8 Spring Lockwashers - SS Cradle Stop Drum Switch Motor only Pully only * Sea Lift Anode Kit (optional) /8"-16 UNC x 1" Hex Head Bolt - SS /8" NC Hex Nut - SS Anode Mounting Small Zinc Anode Assy /8 Lockwasher - SS Page 11 Please order replacement parts by PART NO. and DESCRIPTION * Items used with optional Sea Lift Hoist.

12 DO NOT OPERATE THIS HOIST WITHOUT FIRST STUDYING YOUR OWNER S MANUAL. SAFETY FIRST INSTALLATION INSTRUCTIONS Warning: To Prevent Personal Injury Your electric Dockside Lil'Lifter must be wired according to the National Electrical Code, specifically Article 555-3, which states that the boat hoist must be protected by a ground-fault circuit interrupter located at the shore power. Also the hoist must be grounded according to article Consult a licensed electrician to make sure that your hoist is wired according to local and national electrical codes. 1. Begin by measuring the distance from the top of the dock to the surface of the water.. Position the Dock Plate (#4) in the correct position on the Upright Post (#6) so the watercraft can freely be removed in the lowered position and so the watercraft is safely out of the water in the raised position. Tighten 1/ " nuts. 3. Mount the dock plate (#4) to dock in desired position using four 1/" x -1/" bolts (#1), eight 1/" SS flatwashers (#), and four 1/" hex nuts (#3). 4. Lower the cradle of the hoist into the water just enough to allow the PWC to float on the cradle. 5. Guide the PWC into the Bunk Mounts and center it. 6. Raise the cradle so the PWC just starts to lift and adjust the PWC Bunk Mounts according to the PWC. After final adjustments are made, make sure all fasteners are tight. 7. After making sure no damage will result to either the PWC or the hoist, lift the PWC from the water. CRADLE SETTINGS When the PWC is on the cradle boards the boards should be approximately 18" to 4" out of the water under calm conditions, 30" out of the water under windy conditions. For example, if your PWC is located on an open shore line, the cradle should be set at a height of 30" above the water. If it is located in a sheltered cove it can be set at the 18" to 4" level. This hoist is not a toy, but a piece of equipment that deserves your respect. Before allowing anyone to operate the unit, be sure they read and understand the proper operating procedure. DO NOT EXCEED maximum capacity (1000 lbs) of unit. Overloading of the hoist may cause mechanical failure and serious personal injury. All persons should stand clear of hoist and not be allowed to board your watercraft when it is being raised or lowered. If you choose to inspect or to work on the winch be sure the platform is completely lowered. NEVER PLACE HAND INSIDE THE SHIELD. Children or adults should be restricted from playing on or near the hoist. All persons should be off the watercraft and/or hoist before operating the hoist. If you have a hoist without a canopy, be sure to pull the drain plug in the watercraft before leaving for any length of time. A rain storm could push your gross weight over the hoist capacity. Service the hand winch according to specifications located in the hand winch manual. IMPORTANT: A winch maintenance schedule must be followed to avoid possible failure and injury. When the hoist is in the up position and the hoist is unattended, the electric power should be turned off to the hoist. Check cable for wear or fraying and also stress on cable attaching ends. If this occurs, replace cable immediately. Be sure hoist is installed level. Out-of level installation could cause hoist hangup and serious personal injury. Do not work on your watercraft or hoist with the watercraft on the hoist. Check the sheave to make sure it is turning and operating properly. Lubricate periodically. Service the Electric Motor and Winch regularly. IMPORTANT: A Motor and Winch maintenance schedule must be followed to avoid possible failure and injury. Page 1

13 Dethmers Manufacturing Company th Street Box 189 Boyden, Iowa 5134 Toll Free DEMCO ( ) FAX Warranty Registration Very Satisfied Satisfied Dissatisfied Ag RV Rental Brakes Marine Very Dissatisfied How satisfied are you with our product? How satisfied are you with the dealership/distributor sales staff? Dealer/Distributor Name City State How satisfied are you with the company sales staff? How satisfied are you with the delivery? Did you have any contact with a Demco Representative? YES NO If YES, how satisfied were you? I would recommend this product to my family and friends. YES NO Would you purchase again from DEMCO? YES NO Since taking delivery, have you been contacted by the dealer? YES NO Did you have any problems with this DEMCO product? YES NO If YES, are you satisfied with the company s resolution of your problem? Why did you purchase this product? Please list the specific source of information prompting this purchase. After purchasing this product, do you see any needed product improvement? If yes, what improvement? What other products would you like to see DEMCO offer? Comments Owner s Name: Mailing Address: City: State: Zip Code: Model#: Serial #: Purchase Date: Owner s Signature: Please return to DETHMERS MFG. CO. By FAX or tri-folding this form to the backside, it is pre-addressed. Page 13

14 Postage Dethmers Manufacturing Company th Street, Box 189 Boyden, Iowa 5134 Page 14

15 NOTES Page 15

16 DETHMERS MFG. COMPANY th St., P.O. BOX 189, BOYDEN, IA PH: (71) 75-1 FAX: (71) TOLL FREE: DEMCO ( ) Page 16